Ratcheting mechanism

ABSTRACT

A ratcheting mechanism for a hand-held tool is provided. The mechanism includes a housing having a central opening and a pair of slots disposed on opposite sides of the opening. Each slot has an arcuate or circular end portion opposite the central opening which circumscribes an arc of greater than 180° in order to pivotally retain a generally circular stem of a pawl therein. Due to the presence of a pair of biasing members within the housing, each pawl is biased inwardly towards the central opening and into engagement with teeth located on the exterior of a gear rotatably disposed within the central opening. A cap rotatably connected to the housing over the pawls and the central opening is able to selectively disengage one of the pawls to allow the rotation of the gear within the central opening in a specified direction.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/232,634, filed Sep. 22, 2005, now U.S. Pat. No. 7,156,216, which is acontinuation of U.S. patent application Ser. No. 10/969,402, filed onOct. 20, 2004, now U.S. Pat. No. 6,948,605, which is a continuation ofU.S. patent application Ser. No. 10/342,707, filed on Jan. 15, 2003, nowU.S. Pat. No. 6,817,458, which claims priority from U.S. ProvisionalPatent Application Ser. No. 60/348,516, filed on Jan. 16, 2002.

FIELD OF THE INVENTION

The present invention relates to a ratcheting mechanism, and morespecifically to a ratcheting mechanism for use in a hand-held tool.

BACKGROUND OF THE INVENTION

Screwdrivers and other hand-held tools are often utilized to insert,remove and/or adjust fasteners attached to various items. The tool isused to rotate the fasteners into or out of apertures in the items toproperly position the fasteners with respect to the items.

In order to make the rotation of the fasteners easier when utilizingthese tools, the tools often include ratcheting mechanisms which enablethe tool to apply a force to the fastener when the tool is rotated inone direction, and to allow the tool to rotate freely without applying aforce to the fastener in the opposite direction. Ratcheting mechanismsof this type take various forms, such as those disclosed in U.S. Pat.Nos. 5,613,585; 5,619,891; 5,778,743; 5,873,288; and 5,943,755. In eachof these mechanisms, a pair of pawls is disposed within a housing forthe tool. The pawls can be selectively engaged and disengaged from atoothed gear disposed within the tool housing in order to enable thegear to rotate in a specified direction to achieve the desiredmechanical advantage when adjusting, inserting or removing a fastener.

However, while tools incorporating ratcheting mechanisms of this typeare useful in adjusting, inserting and removing fasteners from variousitems, the mechanisms also have certain drawbacks. For example, due tothe shape of the pawls and the corresponding placement of the pawlswithin the housing, prior art ratcheting mechanism constructions areunable to handle large amounts of torque without the teeth on the gearslipping past the pawls. Thus, for fasteners that are very tightlyengaged with an item, mechanisms of this type effectively cannot be usedto adjust, insert or remove the fasteners. Additionally, due to thelarge size and consequent spacing of the teeth on the gear, the toolmust be rotated more than approximately 10° in order to advance theratcheting mechanism to the next locking position. In situations whereprecise movements of a fastener are necessary, the tools incorporatingmechanisms of the above-referenced type with gears of this size are notsuitable as these mechanisms are very “coarse” and do not allow forprecise movements of the fastener. Further, the prior art ratchetingmechanisms require a large number of parts to be assembled within thehousing in order to complete the ratcheting mechanism, increasing thetime and expense necessary for manufacturing tools incorporating theseprior art ratcheting mechanisms.

Therefore, it is desirable to develop a ratcheting mechanism forhand-held tools that has a simple and easy to assemble construction, andthat also provides the tool with the ability to easily and preciselyadjust the position of a fastener on an item, no matter how securely thefastener is engaged with the item.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a ratchetingmechanism for a tool in which the pawls for the ratcheting mechanism arerotatably retained within elongate, arcuate slots positioned in ahousing for the mechanism to enable the mechanism to accommodate largeamounts of torque exerted on the mechanism without the mechanismslipping on the fastener.

It is another object of the present invention to provide a ratchetingmechanism for a tool in which the biasing members used to maintain thepawls in engagement with a toothed gear in the mechanism have aneasily-assembled construction.

It is a further object of the present invention to provide a ratchetingmechanism for a tool in which the pawls and the biasing members arereliably positioned and retained within spaces formed directly in thehousing for the mechanism without the need for any additional fasteners.

It is still another object of the present invention to provide aratcheting mechanism for a tool including a rotatable gear having alarge number of reduced-size teeth that allow the rotation of themechanism and an associated fastener to be precisely controlled in orderto accurately position the fastener.

It is still a further object of the present invention to provide aratcheting mechanism for a tool which can be incorporated into a widevariety of tools for use in various applications.

The present invention is a ratcheting mechanism for use in a hand-heldtool that is utilized to rotate a fastener, such as a screw, nail orbolt, among others, with regard to an item or object in which thefastener is positioned. The mechanism includes a housing that can beattached to or formed as part of a handle that is grasped in order touse the tool. The mechanism further includes a rotatable, toothed geardisposed within the center of the housing that is engaged by a pair ofpivotable pawls disposed on opposite sides of the opening. The teeth onthe gear are sized and positioned such that the gear need only berotated a small distance in order to result in a displacement of onefull tooth on the gear, i.e., to a successive locking position for thegear.

The pawls on each side of the gear are preferably formed as elongatemembers that each includes a generally circular stem and an armextending outwardly from the stem that is engageable with the teeth onthe gear. The stem is received within an arcuate portion of one of apair of slots disposed on opposite sides of the gear. The arcuateportions of each slot enclose an angle of greater than 180° such thatthe stem of each pawl is reliably held within, yet allowed to pivot,easily with respect to, the slot. Each pawl is biased into engagementwith the teeth on the gear by a biasing member positioned adjacent theslot and in engagement with the pawl. The biasing member is preferablyformed by a pin inserted into an opening in the housing and intoengagement with a biasing element extending between the hole for the pinand the slot for the pawl that contacts and biases the pawl intoengagement with the gear.

The direction of the rotation of the gear within the housing iscontrolled by a cap rotatably connected to the housing over the pawls,the biasing members and the gear. The cap includes a pair of opposedrecesses that are positioned over the housing in alignment with thepawls. When the cap is rotated in one direction or the other, one of therecesses engages the adjacent pawl to urge the pawl out of engagementwith the gear against the bias of the biasing member. Further, becausethe cap includes a pair of recesses, each selectively engageable withone of the pawls, the cap allows the gear to be rotated in both aclockwise and counterclockwise direction with respect to the housingsuch that the mechanism allows for driving and removal of the fastener.The cap can also be positioned with respect to the housing such thatboth pawls are positioned in engagement with the gear in order tomaintain the gear in a stationary position within the housing.

Numerous other features, objects and advantages of the present inventionwill be made apparent from the following detailed description takentogether with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode currently contemplated ofpracticing the present invention.

In the drawings:

FIG. 1 is an isometric view of a tool incorporating the ratchetingmechanism of the present invention;

FIG. 2 is an isometric view of the ratcheting mechanism of FIG. 1;

FIG. 3 is an exploded view of the ratcheting mechanism of FIG. 2;

FIG. 4 is a front plan view of the ratcheting mechanism of FIG. 2;

FIG. 5 is an isometric view of the cap of the ratcheting mechanism ofFIG. 3;

FIG. 6 is a side plan view of the tool including a second embodiment ofthe cap of FIG. 1;

FIG. 7 is an isometric view of the cap of FIG. 6; and

FIG. 8 is an isometric view of a second embodiment of a spring used inthe mechanism of FIG. 2.

DETAILED DESCRIPTION OF THE DRAWINGS

With reference now to the drawing figures in which like referencenumerals designate like parts throughout the disclosure, a hand-heldtool for positioning a fastener with respect to an object is indicatedgenerally at 10 in FIG. 1. The tool 10 includes a handle 12 that isformed of a generally rigid material that is easily gripped by anindividual utilizing the tool 10, such as a metal, a wood, or a hardplastic. The handle 12 is connected to an implement 16 at one end thatextends outwardly through a cap 14 rotatably connected to the handle 12around the implement 16. The implement 16 can be any suitable type ofinstrument utilized to remove, adjust or tighten a fastener (not shown),such as a Phillips or flathead screwdriver implement, or a ratchet headimplement, as is known in the art.

Referring now to FIGS. 2-5, the tool 10 includes a ratcheting mechanism18 that is disposed within a housing 20. The housing 20 can be formedseparately of the same or a similar material as the handle 12, but canalso be formed integrally with the handle 12 in a preferred embodimentby machining the various openings formed in the housing 20 directly intothe handle 12. In the embodiment where the housing 20 is formedseparately from the handle 12, the housing 20 includes a wide first end22, and a narrow second end 24 joined by a tapering, conical wall 25which is positioned within the handle 12 and is used to secure thehousing 20 to the handle 12. The housing 20 can be fixed to the handle12 using any suitable means, such as a mechanical fastener (not shown),an adhesive, or any suitable bonding technique such as thermal or sonicwelding depending upon the types of materials used to form the handle 12and the housing 20.

The wide end 22 includes a generally circular central opening 26 thatextends inwardly into the housing 20 towards the narrow end 24. A pairof elongate slots 28 is disposed on opposite sides of the opening 26 andextends generally radially and tangentially outwardly from the opening26. However, the slots 28 can also be offset from one another such thatthe slots 28 are not aligned or positioned as mirror images of eachother. Each slot 28 defines a nesting portion 30 opposite the centralopening 26 that is generally circular or arcuate in shape, andcircumscribes an arc of greater than 180°. More preferably, the nestingportion 30 encompasses an arc of greater than 200° but not more than250° to allow for sufficient movement within the portions 30.

The shape of each nesting portion 30 is designed to pivotally receiveand securely retain a pawl 32 therein. The pawls 32 are generallyelongate members formed of a rigid material, such as a metal or hardplastic, that include a stem 34 having a generally circularcross-section and a diameter slightly less than the inner diameter ofthe nesting portion 30. The pawls 32 further include an arm 36 extendingoutwardly from the stem 34 and having a length sufficient to extend fromthe nesting portion 30 through the remainder of the slots 28 and intothe central opening 26. The arm 36 is generally rectangular in shape andincludes an outer end 38 that is positionable within the central opening26. The overall length of the pawl 32 is such that when the pawls 32 areinserted fully into each slot 28 within the housing 20, a portion ofeach pawl 32 is positioned outwardly of the housing 20 such that thepawls 32 can be engaged by the cap 14 in a manner to be described.

The outer end 38 of the arm 36 of each pawl 32 is positionable withinthe central opening 26 in order to engage one of a number of teeth 40disposed on an outer surface 42 of a gear 44 rotatably disposed in theopening 26. The teeth 40 are formed of a size sufficient to enable thegear 44 to be rotated through an angle of about 10° in order to move thewidth of a single tooth 40. Therefore, the size of the teeth 40 allowsfor very small movements of the gear 44 with respect to the housing 20providing a “smooth” feel to the tool 10 so that a fastener engaged bythe tool 10 can be very precisely adjusted. Also, because the smallersize for the teeth 40 enables the teeth 40 to be positioned further froma central axis 45 of the gear 44, less stress or force is applieddirectly to the interface of the pawls 32 and the teeth 40, lesseningthe chance of the pawls 32 slipping over the teeth 40.

The gear 44 is generally cylindrical in shape including a first section46 of the outer surface 42 on which the teeth 40 are disposed, and asecond section 48. As best shown in FIG. 3, the outer diameter of thefirst section 46 of the gear 44 defined by the teeth 40 is slightly lessthan the inner diameter of the central opening 26, such that the gear 44can rotate freely within the central opening 26 without interferencefrom the housing 20. The gear 44 further defines a central aperture 50extending into and through the first portion 46, and including a numberof spaced grooves 52 that extend the length of the aperture and whichare adapted to receive and engage complementary ridges (not shown)disposed on the implement 16 in order to securely hold the implement 16within the gear 44 and prevent slipping of the implement 16 with respectto the gear 44.

The gear 44 is effectively prevented from rotating within the centralopening 26 of the housing 20 by the engagement of the pawls 32 with theteeth 40 on the gear 44. The pawls 32 are biased into engagement withthe teeth 40 by a pair of biasing members 54 disposed on opposite sidesof the central opening 26 adjacent each slot 28. Each of the biasingmembers 54 preferably includes a generally cylindrical pin 56 formed ofa rigid material that is inserted into an elongate pin hole 58 locatedin the housing 20 adjacent each slot 28. The length of each pin 56 issimilar to the length of each pawl 32, such that when the pins 56 areinserted into the holes 58, the pins 56 extend outwardly from thehousing 20 a short distance.

Each pin 56 is inserted through a central, looped portion 60 of atorsion spring 62 in order to anchor the spring 62 within the housing20. While the spring 62 is a preferred biasing element for use in thebiasing members 54, other suitable elements can also be used, such as aresilient, deformable plastic member, or a leaf spring, among others. Toanchor the spring 62, the central section 60 is inserted into the pinhole 58 for engagement by the pin 56 through a channel 64 that extendsbetween and intersects both the pin hole 58 and the slot 28. Thus, afirst leg 66 of the spring 62 is positioned along the channel 64 betweenthe pin hole 58 and slot 28, while a second leg 68 is biased outwardlyby the central portion 60 and first leg 66 into engagement with the pawl32 as best shown in FIG. 4. The engagement of the second leg 68 with thepawl 32 maintains the outer end 38 of the arm 36 in engagement with theteeth 40 on the gear 44 to prevent rotation of the gear 44 in adirection toward the respective pawl 32. Further, in a second embodimentof the spring 62, as shown in FIG. 7, the first leg 66 and second leg 68can be oriented on the central section 60 to extend outwardly from thecentral section 60 at an angle of approximately 90° with respect to oneanother. The increased angular distance between the first leg 66 andsecond leg 68 allows for an increase in the range and strength of thebiasing force exerted by the spring 62 on the arm 38 of the pawl 32 toeven further prevent slippage of the pawl 32 with respect to the teeth40. The first leg 66 may also include a tab 69 disposed opposite thecentral portion 60. The tab 69 is insertable into an opening (not shown)in the channel 64 adjacent the nesting portion 30 of the slot 28 inorder to ensure the proper positioning of the central portion 60 of thespring 62 within the pin hole 58 to allow easy insertion of the pin 56through the central portion 60.

Referring now to FIG. 5, the pawls 32 are maintained in or disengagedfrom the teeth 40 on the gear 44 by one of a pair of recesses 70disposed on an interior surface 72 of the cap 14. Each recess 70 has awide end 74, and a narrow end 76 that are separated by an inwardlyextending ridge 78. The portion of each pawl 32 extending outwardly fromthe slots 28 is positioned within one of the recesses 70 on the cap 14when the cap 14 is secured to the housing 20. When the cap 14 is rotatedover the housing 20 such that a ridge 78 of one of the recesses 70 comesinto contact with the adjacent pawl 32, the pawl 32 is urged out of thecentral opening 26 away from the teeth 40 against the bias of thebiasing member 54 to a disengaged position, as shown best in FIG. 4. Inthis position, the gear 44 is allowed to rotate in a direction towardthe disengaged pawl 32, as the opposite pawl 32 is configured to allowrotation in this direction, but to prevent any rotation in the oppositedirection.

In order to assist an individual in properly positioning the cap 14 toenable the recesses 70 on the cap 14 to control the rotation of the gear44 in one direction or the other, the cap 14 includes a number ofdepressions 80 disposed between the pair of recesses 70. Each of thedepressions 80 is engageable with a spring-biased detent 82 positionedon the housing 20 between the pin holes 58. When the cap 14 is rotated,the detent 82 is compressed inwardly into an opening (not shown)disposed in the housing 20 that retains the detent 82 such that the cap14 can rotate above the detent 82. However when one of the depressions80 is positioned in alignment with the detent 82, a spring (not shown)positioned within the opening between the housing 20 and the detent 82urges the detent 82 outwardly into engagement with the depression 80.The cap 14 is thus held in this position until such time as a sufficientforce is applied by an individual to the cap 14 to disengage thedepression 80 from the detent 82. Further, to prevent the cap 14 frombeing rotated past the outermost depressions 80, the wide end 74 of eachrecess 70 is configured to engage the outwardly extending end of eachpin 56 which functions as a stop for the rotation of the cap 14 withrespect to the housing 20.

The cap 14 can be rotatably secured to the exterior of the housing 20 inany conventional manner, but as shown in FIGS. 2 and 4, is preferablysecured to the housing 20 by the engagement of a circumferential clip 84disposed on the exterior of the wide end 22 of the housing 20 with acorresponding groove 86 disposed on the interior surface 72 of the cap14. The engagement of the clip 84 and the groove 86 enables the cap 14to rotate with respect to the housing 20 as necessary withoutdisengaging the cap 14 from the housing, unless desired. Further, byengaging the clip 84 within the groove 86, a central opening 88 definedin the cap 14 is positioned in alignment with the central aperture 50 ofthe gear 44. Thus, the implement 16 can be inserted through the opening88 in the cap 14 and into engagement with the aperture 50 in the gear 44in order to be utilized with the ratcheting mechanism 18 of the tool 10.Also, to assist in rotating the cap 14, the cap 14 can be formed of anysuitable material, such as a metal or a suitably rigid plastic, that canhave added grip enhancements, such as knobs (not shown) or other highfriction structures, or materials. However, preferably, the cap 14includes a number of grooves 90 on the exterior surface 92 of the cap 14that facilitate the gripping of the cap 14 by an individual and mostpreferably the exterior surface 92 of the cap 14 includes a knurledportion 94 as shown in FIGS. 6 and 7.

Various alternatives are contemplated as being within the scope of thefollowing claims particularly pointing out and distinctly claiming thesubject matter regarded as the invention.

1. A ratcheting mechanism for a tool, the ratcheting mechanismcomprising: (a) a housing including at least one slot including agenerally arcuate end and an open end disposed generally opposite thearcuate end; (b) at least one pawl disposed within the at least oneslot, the at least one pawl including a generally circular stem at oneend that is rotatably engaged within and retained by the arcuate end ofthe at least one slot; (c) at least one biasing member engaged with theat least one pawl to bias the at least one pawl inwardly. (d) a caprotatably connected to the housing, the cap including at least onerecess aligned with and disposed at least partially above the at leastone slot in the housing and including an engagement surface engageablewith the at least one pawl to selectively move the at least one pawloutwardly against the bias of the at least one biasing member.
 2. Themechanism of claim 1 wherein the at least one recess further includes astop surface spaced from the engagement surface and engageable with thehousing to limit the rotation of the cap with respect to the housing. 3.The mechanism of claim 2 wherein the housing further includes at leastone stop member extending outwardly from the housing and engageable withthe stop surface of the at least one recess to limit the rotation of thecap with respect to the housing.
 4. The mechanism of claim 3 wherein theat least one stop member is spaced from the at least one slot.
 5. Themechanism of claim 1 wherein the at least one biasing member has a firstend secured within a bore formed in the housing and spaced from the atleast one slot.
 6. The mechanism of claim 5 wherein the at least onebiasing member extends linearly across the at least one slot intoengagement with the at least one pawl.
 7. The mechanism of claim 6wherein a second end of the at least one biasing member engages arectangular section of the at least one pawl that is secured to thegenerally circular stem.
 8. The mechanism of claim 5 wherein the atleast one biasing member extends across the at least one slot generallyperpendicularly to the rotational axis of the circular stem of the atleast one pawl.